Mineral composite panel and its production process

ABSTRACT

The various embodiments herein provide a prefabricated mineral composite panel and a method for producing the prefabricated mineral composite panel for constructing the internal walls and the lateral walls in a building. The method comprising the steps of: preparing and assembling a cast, fixing a mesh in the cast, pouring a prefabricated mineral composite into the cast, smoothening and flattening a top surface of the cast, disassembling the cast to withdraw a semi-dried prefabricated mineral composite panel, placing the semi-dried prefabricated mineral composite panel in a drying room for drying the prefabricated mineral composite, removing the dried prefabricated mineral composite panel from the drying room and packaging the prefabricated mineral composite panel.

BACKGROUND

1. Technical Field

The embodiments herein generally relate to a building and constructionindustry and particularly relate to a partition wall inside thebuildings. The embodiments herein more particularly relate to aprefabricated light weight panel for interior and lateral walls in thebuildings and a method of fabricating light weight panel. Theembodiments herein relate to a light weight and earthquake resistantmineral composite panel for internal walls and lateral walls inbuildings and a method of fabricating the same.

2. Description of the Related Art

Since ancient times, gypsum has been one of the basic materials used ina building construction. A Plaster is made from baking and grinding thegypsum. The Gypsum is a member of the calcium containing constructionmaterials abundantly found in nature and is available in almost allparts of the earth. It ranks fifth in terms of natural occurrence. TheCalcium sulfate occurs in two forms in nature.

Gypsum or hydrated calcium sulfate, with the chemical formula CaSo₄.2H₂O, occurs in nature in the form of spear-shaped crystals, filaments,finely-grained masses (alabaster). Gypsum belongs to the monocliniccrystal system and has a specific gravity of 2.32 and a hardness of 2.Gypsum has low relief and weak birefringence.

Anhydrite or anhydrous calcium sulfate, with the chemical formula CaSO4,is orthorhombic and has a specific gravity of 2.89-2.98 and a hardnessof 3-3.35. The Anhydrite or anhydrous calcium sulfate has a moderatebirefringence and a higher relief.

During the past recent years, blocks of plaster have been manufacturedand marketed as a type of prefabricated walls, for serving such purposesas constructing walls and partitions. However, they have not been widelyused due to their high weight and non-resistance to earthquake orsimilar events.

The large-scale and growing need for housing and buildings has made itessential to employ modern methods and materials with the aim ofspeeding up construction, reducing weight of buildings, increasing lifeexpectancy and strengthening buildings against earthquake more than everbefore. The problems such as the longer periods of construction, a shortlife expectancy, and a high cost of construction require a propersolution such as the scientific use of modern methods and modernbuilding materials to reduce a weight of building and building material,reduce a construction time, enhance the durability of building andbuilding material, and ultimately reduce the construction costs.

Reducing a building weight is one of the modern issues in theconstruction science and industry and is expanding and advancing day byday. This technology involves the reduction of the final weight of abuilding by means of employing modern techniques, using new constructionmaterials, optimizing construction methods, and reducing the buildingweight thereby not only saving costs, time and energy, but alsomitigating the damages arising from the natural disasters such asearthquake and minimizes the damages arising largely from the weight ofthe building. To employ weight reduction (lightening) techniques, thereasons behind the heaviness of buildings, must be properly addressed atfirst. Once these reasons are identified, efforts should be made toeither eliminate or minimize their effect on the final weight of thebuilding.

The lesser the weight of the structure, the lesser the energy absorbedfrom earthquakes, and thus the seismic effect of the earthquake to thebuilding is reduced. In other words, reducing a weight of (lightening) abuilding means providing a more safety against earthquakes.

The use of traditional and old construction materials such as bricks notonly adds to the magnitude of the dead load of a building but alsoincreases an energy consumption thereby practically wasting energy.Moreover, a low erection speed and a high volume of building rubblearising from the use of such materials are among the other problemsarising with the use of such traditional materials.

On the other hand, as the weight of a building increases, the cost priceof the building structure also increases thereby ultimately leading to arise in the cost price of the building. These issues can be consideredas part of the numerous problems faced by this market.

One of the prior arts provides a gypsum based panel such asplasterboard. The panels are manufactured by mounting the rigid boardmaterials onto a frame and applying the facing material to the boardwith a bonding agent. The cited prior art disclosed herein fails toincrease the speed of building production. Also, the cost price ofconstructing the buildings is high.

However, with the use of the present day prior art panels, the costprice for constructing the buildings are high. Also, the structural andbuilding weights are high.

In the view of the foregoing description, there is a need for aprefabricated panel that reduces a structural and building weight.Further, there is a need for a prefabricated panel that controls anenergy consumption in the buildings and reduces its wastage. Stillfurther, there is a need for a panel that increases a speed ofconstructing the internal walls and lateral walls in the buildings andthereby reducing a cost price of a construction.

The abovementioned shortcomings, disadvantages and problems areaddressed herein and which will be understood by reading and studyingthe following specification.

OBJECTS OF THE EMBODIMENTS

The primary object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building.

Another object of the embodiments herein is to provide a method forerecting a prefabricated mineral composite panel.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building thereby reducing a heavinessof the construction materials.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building to reduce the structural andbuilding weights.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and lateral walls in a building to provide a fire resistant panel.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and lateral walls in a building to control energy consumption inthe building and to prevent wastage of large quantities of energy.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and lateral walls in a building to prevent a generation of a highvolume of building rubble

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and lateral walls in a building to increase a speed of a buildingconstruction.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing internal wallsand lateral walls in a building to reduce a cost price of theconstruction

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building to increase a safety ofbuilding walls against fire and earthquake.

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building to achieve an independentknow-how and production technology to eliminate a need for the importsand reliance on the foreign sources

Yet another object of the embodiments herein is to provide aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building to increase the acousticimpedance thermal resistance factors

These and other objects and advantages of the embodiments herein willbecome readily apparent from the following detailed description taken inconjunction with the accompanying drawings.

SUMMARY

The various embodiments herein provide a prefabricated mineral compositepanel and a method for producing a prefabricated mineral composite panelfor constructing the internal walls and the lateral walls in a building.According to an embodiment herein, the method comprising the steps ofpreparing and assembling a cast, fixing a mesh in the cast, pouring aprefabricated mineral composite into the cast, smoothening andflattening a top surface of the cast, disassembling the cast to withdrawa semi-dried prefabricated mineral composite panel, placing thesemi-dried prefabricated mineral composite panel in a drying room fordrying the prefabricated mineral composite, removing the driedprefabricated mineral composite panel from the drying room and packagingthe prefabricated mineral composite panel.

According to an embodiment herein, a plurality of prefabricated mineralcomposite panels are fixed together to form an internal wall and alateral wall in a building.

According to an embodiment herein, the prefabricated mineral compositepanel is dried in the drying room at a temperature of 50° Celsius.

According to an embodiment herein, the mesh is a polypropylene plasticmesh or a fiber glass mesh.

According to an embodiment herein, the prefabricated mineral compositefor constructing the internal walls and lateral walls in the buildingscomprises a plurality of dry materials and a plurality of wet materials.

According to an embodiment herein, the plurality of dry materialscomprises an industrial alpha gypsum with a ratio of 15%, an industrialbeta gypsum with a ratio of 50%, calcium carbonate with a ratio of 20%,sodium bentonite with a ratio of 4%, perlite with a ratio of 10%, sodiumchloride with a ratio of 1% and slender polypropylene fibers with aratio of 0.05%.

According to an embodiment herein, the plurality of wet materialscomprises water with a ratio of 95%, late resin stuck with a ratio of 2%and waterproof resin with a ratio of 3%.

According to an embodiment herein, the plurality of dry materials aremixed together in a dry form to form a mixture of dry materials and theplurality of wet materials are added to the mixture of the dry materialsand mixed for a specific period of time.

According to an embodiment herein, the mineral composite are mixedtogether for a time period of 60 minutes.

The various embodiments herein provide a method for erecting theprefabricated mineral composite panels. The method comprises the stepsof placing a plurality of galvanized iron angles perpendicular to aceiling, spraying water on a prefabricated mineral composite panel,placing a wetted prefabricated mineral composite panel against thegalvanized iron angles, placing the galvanized iron angles against thepanel for ensuring a proper placement of panel in place, connecting aplurality of panels to one another and applying a mineral adhesivebetween the panels for fixing the panels to one another firmly.

These and other aspects of the embodiments herein will be betterappreciated and understood when considered in conjunction with thefollowing description and the accompanying drawings. It should beunderstood, however, that the following descriptions, while indicatingpreferred embodiments and numerous specific details thereof, are givenby way of illustration and not of limitation. Many changes andmodifications may be made within the scope of the embodiments hereinwithout departing from the spirit thereof, and the embodiments hereininclude all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

The other objects, features and advantages will occur to those skilledin the art from the following description of the preferred embodimentand the accompanying drawings in which:

FIG. 1A illustrates a front perspective view of a prefabricated mineralcomposite panel, according to an embodiment herein.

FIG. 1B illustrates a top side view of a prefabricated mineral compositepanel, according to an embodiment herein.

FIG. 1C illustrates a front side view of a prefabricated mineralcomposite panel, according to an embodiment herein.

FIG. 1D illustrates a side view of a prefabricated mineral compositepanel, according to an embodiment herein.

FIG. 2 illustrates a flow chart explaining a method for producing aprefabricated mineral composite panel, according to an embodimentherein.

FIG. 3A illustrates a perspective view of a door space erected with aprefabricated mineral composite panel, according to an embodimentherein.

FIG. 3B illustrates a perspective view of a window space erected with aprefabricated mineral composite panel, according to an embodimentherein.

FIG. 4 illustrates a flow chart explaining a method for erecting aprefabricated mineral composite panel for constructing internal wallsand lateral walls in a building, according to an embodiment herein.

Although the specific features of the embodiments herein are shown insome drawings and not in others. This is done for convenience only aseach feature may be combined with any or all of the other features inaccordance with the embodiments herein.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In the following detailed description, a reference is made to theaccompanying drawings that form a part hereof, and in which the specificembodiments that may be practiced is shown by way of illustration. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice the embodiments and it is to be understood thatthe logical, mechanical and other changes may be made without departingfrom the scope of the embodiments. The following detailed description istherefore not to be taken in a limiting sense.

The various embodiments herein provide a prefabricated mineral compositepanel and a method for producing a prefabricated mineral composite panelfor constructing the internal walls and the lateral walls in a building.According to an embodiment herein, the method comprising the steps ofpreparing and assembling a cast, fixing a mesh in the cast, pouring aprefabricated mineral composite into the cast, smoothening andflattening a top surface of the cast, disassembling the cast to withdrawa semi-dried prefabricated mineral composite panel, placing thesemi-dried prefabricated mineral composite panel in a drying room fordrying the prefabricated mineral composite, removing the driedprefabricated mineral composite panel from the drying room and packagingthe prefabricated mineral composite panel.

According to an embodiment herein, a plurality of prefabricated mineralcomposite panels are fixed together to form an internal wall and alateral wall in a building.

According to an embodiment herein, the prefabricated mineral compositepanel is dried in the drying room at a temperature of 50° Celsius.

According to an embodiment herein, the mesh is a polypropylene plasticmesh or a fiber glass mesh.

According to an embodiment herein, the prefabricated mineral compositefor constructing the internal walls and lateral walls in the buildingscomprises a plurality of dry materials and a plurality of wet materials.

According to an embodiment herein, the plurality of dry materialscomprises an industrial alpha gypsum with a ratio of 15%, an industrialbeta gypsum with a ratio of 50%, calcium carbonate with a ratio of 20%,sodium bentonite with a ratio of 4%, perlite with a ratio of 10%, sodiumchloride with a ratio of 1% and slender polypropylene fibers with aratio of 0.05%.

According to an embodiment herein, the plurality of wet materialscomprises water with a ratio of 95%, late resin stuck with a ratio of 2%and waterproof resin with a ratio of 3%.

According to an embodiment herein, the plurality of dry materials aremixed together in a dry form to form a mixture of dry materials and theplurality of wet materials are added to the mixture of the dry materialsand mixed for a specific period of time.

According to an embodiment herein, the mineral composite are mixedtogether for a time period of 60 minutes.

The various embodiments herein provide a method for erecting theprefabricated mineral composite panels. The method comprises the stepsof placing a plurality of galvanized iron angles perpendicular to aceiling, spraying water on a prefabricated mineral composite panel,placing a wetted prefabricated mineral composite panel against thegalvanized iron angles, placing the galvanized iron angles against thepanel for ensuring a proper placement of panel in place, connecting aplurality of panels to one another and applying a mineral adhesivebetween the panels for fixing the panels to one another firmly.

According to an embodiment herein, a mineral composite panel or block isa product which has been designed and produced in full conformity to theclimatic conditions of the dry and semi-humid geographic regions. Inthis type of mineral composite panel, the weak properties of the basematerials such as a fracture, a weakness toward moisture, and a lowcompressive resistance and a bending strength are modified. To achievethis end, carbonate and clay-based compounds as well as an internal meshare added to the compressive and bending strengths of the originalcompounds as a result of which the weight of the composite mineral panelis reduced greatly and the compressive and bending strengths of thecomposite mineral panel is enhanced to a great extent. The acousticcoefficient of the composite mineral panel is quite high and providesgood noise and thermal insulation.

Furthermore, the composite mineral panel of the embodiments hereinprovides other excellent features such as a low weight, a high bendingand compressive strengths, use of fibers and internal meshing. Thecomposite mineral panel of the embodiments herein, does in no way leadto a collapse or physical injuries in times of earthquakes. Theprefabricated mineral composite panels are fabricated at very reasonableprices compared to other construction materials and provide very higherection speed. In case the use of such prefabricated mineral compositepanels forms the basis of structural design from the very beginning ofthe implementation of a project, the weight of a building can be reducedto great extent, and in turn allowing considerable savings on steel andconcrete.

The prefabricated mineral composite panels of the embodiments herein isformed with a mixture comprising the Polypropylene plastic mesh orfiber-glass mesh, the slender polypropylene or fiber-glass fibers up to30 mm or 20 cm, an industrial alpha gypsum, an industrial beta gypsum,calcium carbonate, sodium bentonite, perlite, salt, reinforcing resin,waterproofing resin and water.

As soon as the mesh is placed in the cast and tied up, the cast is readyfor the mixture of composite materials to be poured into the cast. Theentire mineral raw materials are mixed together in a dry form at therelevant mixing ratios, and then water is added in proportion to itsweight and mixed for a specific period of time as indicated in theproduction instructions. Then, a dough-like mixture is then poured intothe cast and flattened on top. After a specified period of time, theproduct is removed from the cast and is left free on the pallets in theworkshop space so that the mineral composite panel is made to sets-incompletely.

Finally, the mineral composite panel is transferred to the drying(baking) furnace so that the composite panel is dehydrated and becomescompletely dry after the required time. Once removed from the drier, themineral composite panel is ready to be forwarded to the constructionsites for erection purposes.

These mineral composite panels are erected as follows: A number ofpunched galvanized iron angles, having the dimensions of 5×5 cm, isfitted on the ceiling (where the wall is going to be erected), and thepanels are placed against them. Then, a number of angles is fitted infront of it to ensure it stands in place. The panels are connected toone another by means of a special mineral adhesive. To provide therequired hydration between the panels and the special adhesive, thelightweight mineral composite panel of 8 cm or 12 cm is wetted withwater prior to adhesive application and installation. Then, adhesive isapplied and spread evenly. The next panel (after wetting) is placedexactly beside the first one, and this procedure is continued until thewhole wall is completed.

The mineral composite panel is completely waterproof and is resistant toimpact, heat and cold. The mineral composite panel is highly lightweightand reduces structural and building weights. The mineral composite panelallows an energy control and efficiency in buildings and reduces energywastage. The use of mineral composite panel speeds up buildingconstruction works. The mineral composite panel enhances the safety ofbuilding walls against fire and earthquake. The mineral composite panelincreases the acoustic and thermal resistance factors in the buildingwalls.

To better evaluate mineral composite panels, the maximum bending stresson the x axis of the panels (the weakest direction) is calculated by thetwo types of concentrated and distributed loads.

The Bending formula:

$\frac{M}{I} = {\frac{\sigma_{b}}{Y} = \frac{E}{R}}$

Where M is the bending moment which causes bending stress,I is the moment of inertia of the section under stressσb is the bending stressE is the distance to the neutral axisY is the Young's modulusR is the radius of the curvature of the member upon bending

Given our need for force, only the first two fractions are used to solvethe equation.

$\frac{M}{I} = {{\frac{\sigma_{b}}{Y}\mspace{14mu} M} = {{{IX} \times \bullet \; {b/Y}} = {{4^{\prime}291.04 \times {63/23.06}} = {11^{\prime}723.14\mspace{14mu} {kgf}\text{/}{cm}}}}}$

The properties of the mineral composite panel of the embodiments hereinare tabulated below.

Cross section of whole panel A = 18′909.4250 mm² = 189.1 cm² Total panelvolume having the V = 18′909′425 mm³ = length of 1 m 18′909.4 cm³ = 18.9lit Volume of each canal in a length Ac = 12′136.8583 mm² = of 1 m121.37 cm² Gyration radius V_(C) = 12′136′853.3 mm³ = 12′136.85 cm³ =12.14 lit Moment of inertia Axis X = 47.6367 mm Axis Y = 145.8503 mmDistance of neutral axes to walls I_(x) = 42′910′396.5850 mm⁴ = 4791.04cm⁴ I_(y) = 402′247′201.9804 mm⁴ = 40724.72 cm⁴ Minimum compressivestrength X = 60 mm = 6 cm Y = 230.5 mm = 23.06 cm Bending strength 140kg/cm² = _(d)□ Weight per unit volume of  63 kg/cm² = _(b)□ compositematerials of each panel Weight per unit length (1 m) of 9.2 × 10⁻⁴kgf/cm³ an EasyWall panel Weight per unit area of each 16.375 kgf/mpanel Weight per unit volume of 35.597 kgf/m² EasyWall mineral-basedcoating Weight of 1 m² of EasyWall 4.6 kgf coatingwith a thickness of 5mm Weight per unit area of each 40.2 kgf/m² panel including rendering ofone side of coating

FIG. 1A illustrates a front perspective view of a prefabricated mineralcomposite panel, FIG. 1B illustrates a top side view of a prefabricatedmineral composite panel, FIG. 1C illustrates a front side view of aprefabricated mineral composite panel and FIG. 1D illustrates a sideview of a prefabricated mineral composite panel, according to anembodiment herein. With respect to FIG. 1A-FIG. 1D, a plurality of castsis prepared and is assembled together. A polypropylene plastic mesh or afiber-glass mesh 101 is fixed internally to the cast.

According to an embodiment herein, the internal mesh 101 is used toreduce the weight of the prefabricated mineral composite panel 100 andto enhance the compressive and building strength of the prefabricatedmineral composite panel 100. Also, the prefabricated mineral compositepanel 100 does in no way lead to collapse or physical injuries in timesof earthquakes due to the use of internal mesh 101.

According to an embodiment herein, a plurality of dry materials is mixedtogether in a dry form at a relevant mixing ratio for a specific periodof time. A plurality of wet materials is added in proportion to themixture of dry materials and is mixed together for a time period of 60min. After the time period of 60 min, a dough-like mixture ofprefabricated mineral composite comprising a mixture of dry materialsand wet materials is obtained. The dough-like mixture is poured into thecast. A top surface of the cast is smoothened and flattened after theprefabricated mineral composite is completely poured into the cast.

According to an embodiment herein, after a time period of 30 min, thecast is disassembled from the semi-dried mineral composite panel 100.The semi-dried mineral composite panel 100 is left free on pallets in aworkshop space for a time period of 12 hours, so that the panel 100 setscompletely.

According to an embodiment herein, the semi-dried mineral compositepanel 100 is placed in a drying room for a time period of 12 hours, sothat it dehydrates and becomes dry. The panel 100 is dried at a roomtemperature of 50° Celsius in the drying room. After the time period of12 hours, the dried prefabricated mineral composite panel 100 is removedfrom the drying room. The prefabricated mineral composite panel 100 ispackaged and is ready for the erection process.

According to an embodiment herein, the plurality of dry materialscomprises about 15% of industrial alpha gypsum, about 50% of industrialbeta gypsum, about 20% of calcium carbonate, about 4% of sodiumbentonite, about 10% of perlite, about 1% of sodium chloride and 0.05%of slender polypropylene fibers.

According to an embodiment herein, the plurality of wet materialscomprises 95% of water, about 2% of late resin stuck and about 3% ofwaterproof resin.

FIG. 2 illustrates a flow chart explaining a method for producing aprefabricated mineral composite panel, according to an embodimentherein. With respect to FIG. 2, the method for production ofprefabricated mineral composite panel for constructing internal wallsand lateral walls in a building comprises the steps of: preparing andassembling a cast, fixing a mesh in the cast, poring a prefabricatedmineral composite in the cast, smoothing and flattening a top surface ofthe cast, disassembling the cast to withdraw a semi-dried prefabricatedmineral composite panel, placing the semi-dried prefabricated mineralcomposite panel in a drying room, removing the dried prefabricatedmineral composite panel from the drying room and packaging theprefabricated mineral composite panel.

According to an embodiment herein, a plurality of casts is prepared andis assembled together (201). A polypropylene plastic mesh or afiber-glass mesh is fixed internally to the cast (202). The internalmesh is used to reduce the weight of the mineral composite panel and toenhance the compressive and building strength of the mineral compositepanel. A plurality of dry materials is mixed together in a dry form at arelevant mixing ratio for a specific period of time. A plurality of wetmaterials is added in given proportion to the mixture of dry materialsand is mixed together for a time period of 60 min. After the time periodof 60 min, a dough-like mixture of prefabricated mineral compositecomprising a mixture of dry materials and wet materials is obtained. Thedough-like mixture is poured into the cast (203). A top surface of thecast is smoothened and flattened after the prefabricated mineralcomposite is completely poured into the cast (204). After a time periodof 30 min, the cast is disassembled from the semi-dried mineralcomposite panel (205). The semi-dried mineral composite panel is leftfree on pallets in a workshop space for a time period of 12 hours, sothat the panel sets in completely. The semi-dried mineral compositepanel is placed in a drying room for a time period of 12 hours, so thatit dehydrates and becomes completely dry (206). The panel is dried at aroom temperature of 50° Celsius in the drying room. After the timeperiod of 12 hours, the dried prefabricated mineral composite panel isremoved from the drying room (207). The prefabricated mineral compositepanel is packaged and is ready for the erection process (208).

FIG. 3A illustrates a perspective view of a door space erected with aprefabricated mineral composite panel, according to an embodimentherein, while FIG. 3B illustrates a perspective view of a window spaceerected with a prefabricated mineral composite panel, according to anembodiment herein. With respect to FIG. 3A and FIG. 3B, a first set ofpunched galvanized iron angles are placed perpendicular to the ceiling(where the internal wall or lateral wall is going to be erected).

According to an embodiment herein, the prefabricated mineral compositepanels 100 are sprayed with water. The wetted prefabricated mineralcomposite panels 100 are placed against the first set of galvanized ironangles. Further, a second set of galvanized iron angles are fitted infront of the prefabricated mineral composite panels 100. As a result,the prefabricated mineral composite panels 100 are placed in between thefirst and the second set of galvanized iron angles to ensure a properplacement of panels 100 in place.

According to an embodiment herein, the prefabricated mineral compositepanels 100 are connected to one another by means of a special mineraladhesive. The prefabricated mineral composite panels 100 are wettedbefore placing against the galvanized iron angles to provide therequired hydration between the panels 100 and the special mineraladhesive. The special mineral adhesive is applied between theprefabricated mineral composite panels 100 and is spread evenly. Thesame procedure is continued until the whole set of internal walls andthe lateral walls are constructed.

FIG. 4 illustrates a flow chart explaining a method for erecting aprefabricated mineral composite panel for constructing the internalwalls and the lateral walls in a building, according to an embodimentherein. With respect to FIG. 4, the method for erecting a prefabricatedmineral composite panel for constructing the internal walls and thelateral walls in a building comprises the steps of: placing a pluralityof galvanized iron angles perpendicular to a ceiling, spraying water onthe prefabricated mineral composite panels, placing the wettedprefabricated mineral composite panels against the galvanized ironangles, placing the galvanized iron angles against the prefabricatedmineral composite panels for ensuring a proper placement ofprefabricated mineral composite panels in place, connecting a pluralityof prefabricated mineral composite panels to one another and applying amineral adhesive between the prefabricated mineral composite panels forfixing the prefabricated mineral composite panels to one another firmly.

According to an embodiment herein, a first set of punched galvanizediron angles is placed perpendicular to the ceiling where the internalwall or lateral wall is going to be erected (401). The prefabricatedmineral composite panels are wetted with water (402). The wettedprefabricated mineral composite panels are placed against the first setof galvanized iron angles (403). Further, a second set of galvanizediron angles are fitted in front of the prefabricated mineral compositepanels. As a result, the prefabricated mineral composite panels areplaced in between the first and the second set of galvanized iron anglesto ensure a proper placement of the prefabricated mineral compositepanels in place (404). The prefabricated mineral composite panels areconnected to one another by means of a special mineral adhesive (405).The prefabricated mineral composite panels are wetted before placingagainst the galvanized iron angles to provide the required hydrationbetween the prefabricated mineral composite panels and the specialmineral adhesive. The special mineral adhesive is applied between theprefabricated mineral composite panels and is spread evenly.

The prefabricated mineral composite panel of the embodiments herein iscompletely water resistant. The prefabricated mineral composite panel isresistant against sound transfer, heat and fire. The panel is highlylightweight and reduces the structural and building weights. The mineralcomposite panel allows energy control and efficiency in buildings andreduces energy wastage. The prefabricated mineral composite panels areoffered at reasonable price and the use of these prefabricated mineralcomposite panels speeds up the construction of internal walls and thelateral walls in the buildings. The mineral composite panel enhances thesafety of building walls against fire and earthquake. The prefabricatedmineral composite panel increases the acoustic and thermal resistancefactors in the building walls.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the embodiments herein that others can, byapplying current knowledge, readily modify and/or adapt for variousapplications such specific embodiments without departing from thegeneric concept, and, therefore, such adaptations and modificationsshould and are intended to be comprehended within the meaning and rangeof equivalents of the disclosed embodiments. It is to be understood thatthe phraseology or terminology employed herein is for the purpose ofdescription and not of limitation. Therefore, while the embodimentsherein have been described in terms of preferred embodiments, thoseskilled in the art will recognize that the embodiments herein can bepracticed with modification within the spirit and scope of the appendedclaims.

Although the embodiments herein are described with various specificembodiments, it will be obvious for a person skilled in the art topractice the invention with modifications. However, all suchmodifications are deemed to be within the scope of the claims.

1. A method for producing a prefabricated mineral composite panel forconstructing internal walls and lateral walls in a building, the methodcomprising the steps of: preparing and assembling a cast; fixing a meshin the cast; pouring a prefabricated mineral composite into the cast;smoothening and flattening a top surface of the cast; disassembling thecast to withdraw a semi-dried prefabricated mineral composite panel;placing the semi-dried prefabricated mineral composite panel in a dryingroom for drying the prefabricated mineral composite; removing the driedprefabricated mineral composite panel from the drying room; andpackaging the prefabricated mineral composite panel; wherein a pluralityof prefabricated mineral composite panels are fixed together, andwherein the plurality of prefabricated mineral composite panels arefixed together to form an internal wall and a lateral wall in abuilding.
 2. The method according to claim 1, wherein the prefabricatedmineral composite panel is dried in a drying room at a temperature of500 Celsius.
 3. The method according to claim 1, wherein the mesh is apolypropylene plastic mesh.
 4. The method according to claim 1, whereinthe mesh is a fiber glass mesh.
 5. The method according to claim 1,wherein the prefabricated mineral composite for constructing theinternal walls and the lateral walls in the buildings comprises: aplurality of dry materials; industrial alpha gypsum with a ratio of 15%;industrial beta gypsum with a ratio of 50%; calcium carbonate with aratio of 20%; sodium bentonite with a ratio of 4%; perlite with a ratioof 10%; sodium chloride with a ratio of 1%; and slender polypropylenefibers with a ratio of 0.05%; a plurality of wet materials; water with aratio of 95%; late resin stuck with a ratio of 2%; and waterproof resinwith a ratio of 3%; wherein the plurality of dry materials are mixedtogether in a dry form to form a mixture of dry materials and theplurality of wet materials are added to the mixture of dry materials andmixed for a specific period of time.
 6. The method according to claim 1,wherein the mineral composite are mixed together for a time period of 60minutes.
 7. A method for erecting the prefabricated mineral compositepanels, the method comprising the steps of: placing a plurality ofgalvanized iron angles perpendicular to a ceiling; spraying water on aprefabricated mineral composite panel; placing a wetted prefabricatedmineral composite panel against the galvanized iron angles; placing thegalvanized iron angles against the prefabricated mineral composite panelfor ensuring a proper placement of prefabricated mineral composite panelin place; connecting a plurality of prefabricated mineral compositepanels to one another; and applying a mineral adhesive between theplurality of prefabricated mineral composite panels for fixing theprefabricated mineral composite panels to one another firmly.